Simulation method to determine the cold extrusion stress of an automotive shaft
摘要
Cold extrusion manufactures products with greater mechanical resistance. Even today, it is important to study the mechanical stresses during this process. The main objective of this work is to apply a simulation method to determine the stress of cold extrusion of shafts in conical dies. To achieve this objective, experiments were conducted in the laboratory and real scales test. The laboratory test was conducted on a universal testing machine with a capacity of 300 kN. The real test was carried out at an automobile company on a hydraulic press with capacity of 14,000 kN. By analyzing the measured values of the laboratory test as well as the correlation factors with the simulation method, it was possible to calculate the cold extrusion stress of shaft, which, when compared to the values found in the real test, presented results with a deviation of 5%. Besides, other methods for stress calculation were also studied, which enabled to identify the ones that returned a better correlation of the numerical model with experimental tests. The results showed an upper bound by Avitzur and finite element method also were close to the values measured in the tests with a deviation of 5% and 8% respectively. The main conclusion of the present research was that through simulation methods one can indicate corrections to the die design, even before the try-out was carried out, working collaboratively with the upper bound and finite element method.